Laminate of thermoplastic resin film and rubber, inner liner material, and pneumatic tire

ABSTRACT

A laminate of a thermoplastic resin or thermoplastic elastomer composition film and a rubber composition layer, which can be used as an inner liner for a pneumatic tire, with improved adhesive strength at the interface of the thermoplastic resin or thermoplastic elastomer composition film and the rubber composition layer. A laminate comprising a thermoplastic resin or thermoplastic elastomer composition film and a rubber composition layer, the rubber composition containing a rubber component, a condensate of a phenol compound and formaldehyde, and methylene donor and a vulcanizing agent, wherein 2.5-40% by mass of the rubber component is halogenated isomonoolefin-p-alkyl styrene copolymer, the content of the condensate is 0.5-20 parts by mass per 100 parts by mass of the rubber component, and the content of the methylene donor is 0.25-200 parts by mass per 100 parts by mass of the rubber component.

TECHNICAL FIELD

The present invention relates to a laminate of a film of a thermoplasticresin or thermoplastic elastomer composition and a layer of a rubbercomposition, an inner liner material for a pneumatic tire comprising thelaminate, and a pneumatic tire comprising the laminate as an inner linermaterial.

BACKGROUND ART

A pneumatic tire comprising a laminate of a film of a thermoplasticresin or thermoplastic elastomer composition and a layer of a rubbercomposition, wherein the rubber composition comprises a rubbercomponent, a condensate of a phenolic compound and formaldehyde, amethylene donor and a vulcanizing agent, and the vulcanizing agent issulfur or an organic peroxide (Japanese Patent No. 4858654).

CITATION LIST Patent Literature

Patent literature 1: Japanese Patent No. 4858654

SUMMARY OF INVENTION Technical Problem

In a laminate of a film of a thermoplastic resin or thermoplasticelastomer composition film and a layer of a rubber composition which canbe used as an inner liner material of a pneumatic tire, an object of thepresent invention is to further improve the adhesive strength at theinterface between the film of the thermoplastic resin or thermoplasticelastomer composition and the layer of the rubber composition.

Solution to Problem

The inventor of the present invention found that, by using a halogenatedisomonoolefin-p-alkyl styrene copolymer as a part of a rubber componentconstituting a rubber composition in a laminate of a film of athermoplastic resin or thermoplastic elastomer composition and a layerof a rubber composition, and blending a condensate of a phenoliccompound and formaldehyde and a methylene donor in the rubbercomposition, the adhesive strength at the interface between the film ofthe thermoplastic resin or thermoplastic elastomer composition and thelayer of the rubber composition is effectively improved, therebycompleting the present invention.

The present invention is a laminate for a pneumatic tire, comprising afilm of a thermoplastic resin or thermoplastic elastomer composition anda layer of a rubber composition, wherein the rubber compositioncomprises a rubber component, a condensate of a compound represented byformula (1):

wherein R¹, R², R³, R⁴, and R⁵ are each independently hydrogen, ahydroxyl group, an alkyl group having 1 to 8 carbon atoms, or an alkoxygroup having 1 to 8 carbon atoms,

and formaldehyde, a methylene donor, and a vulcanizing agent, whereinthe rubber component comprises from 2.5 to 40% by weight a halogenatedisomonoolefin-p-alkyl styrene copolymer based on the rubber component,and the rubber composition comprises from 0.5 to 20 parts by weight ofthe condensate and from 0.25 to 200 parts by weight of the methylenedonor based on 100 parts by weight of the rubber component.

The present invention includes the following aspects.

[1] A laminate for a pneumatic tire, comprising a film of athermoplastic resin or thermoplastic elastomer composition and a layerof a rubber composition, wherein the rubber composition comprises arubber component, a condensate of a compound represented by formula (1):

wherein R¹, R², R³, R⁴, and R⁵ are each independently hydrogen, ahydroxyl group, an alkyl group having 1 to 8 carbon atoms, or an alkoxygroup having 1 to 8 carbon atoms,

and formaldehyde, a methylene donor, and a vulcanizing agent, whereinthe rubber component comprises from 2.5 to 40% by weight of ahalogenated isomonoolefin-p-alkyl styrene copolymer based on the rubbercomponent, and the rubber composition comprises from 0.5 to 20 parts byweight of the condensate and from 0.25 to 200 parts by weight of themethylene donor based on 100 parts by weight of the rubber component.

[2] The laminate according to [1], wherein a ratio of a content of themethylene donor to a content of the condensate is from 0.5 to 10.

[3] The laminate according to [1] or [2], wherein the thermoplasticresin is at least one selected from the group consisting of polyvinylalcohol, ethylene-vinyl alcohol copolymer, nylon 6, nylon 66, nylon 11,nylon 12, nylon 610, nylon 612, nylon 6/66, nylon MXD6, and nylon 6T.

[4] The laminate according to any one of [1] to [3], wherein thethermoplastic elastomer composition is a composition comprising athermoplastic resin component and an elastomer component dispersed inthe thermoplastic resin component; the thermoplastic resin component isat least one selected from the group consisting of polyvinyl alcohol,ethylene-vinyl alcohol copolymer, nylon 6, nylon 66, nylon 11, nylon 12,nylon 610, nylon 612, nylon 6/66, nylon MXD6, and nylon 6T; and theelastomer component is at least one selected from the group consistingof a halogenated isomonoolefin-p-alkyl styrene copolymer, a maleicanhydride-modified ethylene-α-olefin copolymer, an ethylene-glycidylmethacrylate copolymer, and a maleic anhydride-modified ethylene-ethylacrylate copolymer.

[5] The laminate according to any one of [1] to [4], wherein themethylene donor is at least one selected from the group consisting ofmodified etherified methylol melamine, paraformaldehyde,hexamethylenetetramine, pentamethylenetetramine, andhexamethoxymethylmelamine.

[6] An inner liner material for a pneumatic tire, comprising thelaminate according to any one of [1] to [5].

[7] A pneumatic tire comprising the laminate according to any one of [1]to [5] as an inner liner material.

Advantageous Effects of Invention

The laminate of a film of a thermoplastic resin or a thermoplasticelastomer composition and a layer of a rubber composition of the presentinvention is excellent in the adhesive strength at the interface betweenthe film of the thermoplastic resin or the thermoplastic elastomercomposition and the layer of the rubber composition.

DESCRIPTION OF EMBODIMENTS

The present invention is a laminate for a pneumatic tire, comprising afilm of a thermoplastic resin or thermoplastic elastomer composition anda layer of a rubber composition, wherein the rubber compositioncomprises a rubber component, a condensate of a compound represented byformula (1):

wherein R¹, R², R³, R⁴, and R⁵ are each independently hydrogen, ahydroxyl group, an alkyl group having 1 to 8 carbon atoms, or an alkoxygroup having 1 to 8 carbon atoms,

and formaldehyde, a methylene donor, and a vulcanizing agent, whereinthe rubber component comprises from 2.5 to 40% by weight of ahalogenated isomonoolefin-p-alkyl styrene copolymer based on the rubbercomponent, and the rubber composition comprises from 0.5 to 20 parts byweight of the condensate and from 0.25 to 200 parts by weight of themethylene donor based on 100 parts by weight of the rubber component.

Examples of the thermoplastic resin constituting the film include apolyamide resin, a polyester resin, a polynitrile resin, apolymethacrylate resin, a polyvinyl resin, a cellulose resin, a fluorineresin, an imide resin, a polystyrene resin, and a polyolefin resin.

Examples of the polyamide resin include nylon 6 (N6), nylon 66 (N66),nylon 46 (N46), nylon 11 (N11), nylon 12 (N12), nylon 610 (N610), nylon612 (N612), nylon 6/66 (N6/66), nylon 6/66/12 (N6/66/12), nylon 6/66/610(N6/66/610), nylon MXD6 (MXD6), nylon 6T, nylon 6/6T, nylon 9T, nylon66/PP copolymer, and nylon 66/PPS copolymer.

Examples of the polyester resin include aromatic polyesters such aspolyethylene terephthalate (PET), polybutylene terephthalate (PBT),polyethylene isophthalate (PEI), PET/PEI copolymer, polyarylate (PAR),polybutylene naphthalate (PBN), liquid crystal polyester, andpolyoxyalkylene diimide acid/polybutyrate terephthalate copolymer.

Examples of the polynitrile resin include polyacrylonitrile (PAN),polymethacrylonitrile, acrylonitrile/styrene copolymer (AS),methacrylonitrile/styrene copolymer, methacrylonitrile/styrene/butadienecopolymer.

Examples of the polymethacrylate resin include polymethyl methacrylate(PMMA) and polymethyl methacrylate.

Examples of the polyvinyl type resin include polyvinyl acetate (PVAc),polyvinyl alcohol (PVA), ethylene-vinyl alcohol copolymer (EVOH),polyvinylidene chloride (PVDC), polyvinyl chloride (PVC), vinylchloride/vinylidene chloride copolymer, and vinylidene chloride/methylacrylate copolymer.

Examples of the cellulose resin include cellulose acetate and celluloseacetate butyrate.

Examples of the fluorine-based resin include polyvinylidene fluoride(PVDF), polyvinyl fluoride (PVF), polychlorofluoroethylene (PCTFE), andtetrafluoroethylene/ethylene copolymer (ETFE).

Examples of the imide resin include aromatic polyimide (PI). Examples ofthe polystyrene resin include polystyrene (PS).

Examples of the polyolefin resin include polyethylene (PE) andpolypropylene (PP).

Among these, polyvinyl alcohol, ethylene-vinyl alcohol copolymer, nylon6, nylon 66, nylon 11, nylon 12, nylon 610, nylon 612, nylon 6/66, nylonMXD 6, and nylon 6T are preferable in terms of compatibility betweenfatigue resistance and air blocking property.

For improving processability, dispersibility, heat resistance,antioxidant properties, or the like, the thermoplastic resin may beblended with a blending agent generally blended in the resincomposition, such as a filler, a reinforcing agent, a processing aid, astabilizer, or an antioxidant, to the extent that an effect of thepresent invention is not impaired. From the viewpoint of air blockingproperty and heat resistance, a plasticizer is preferably not blended,but may be blended as long as the plasticizer does not impair an effectof the present invention.

A thermoplastic elastomer composition constituting a film is acomposition comprising a thermoplastic resin component and an elastomercomponent dispersed in the thermoplastic resin component, wherein thethermoplastic resin component constitutes a matrix phase and theelastomer component constitutes a dispersed phase.

As the thermoplastic resin component constituting the thermoplasticelastomer composition, the same thermoplastic resin as described abovecan be used.

Examples of the elastomer component constituting the thermoplasticelastomer composition include diene rubber and hydrogenated productthereof, olefinic rubber, halogen-containing rubber, silicone rubber,sulfur-containing rubber, and fluororubber.

Examples of the diene rubber and hydrogenated product thereof includenatural rubber (NR), isoprene rubber (IR), epoxidized natural rubber,styrene butadiene rubber (SBR), butadiene rubber (BR) (high cis BR andlow cis BR), acrylonitrile butadiene rubber (NBR), hydrogenated NBR, andhydrogenated SBR.

Examples of the olefin rubber include ethylene propylene rubber (EPM),ethylene propylene diene rubber (EPDM), maleic acid-modified ethylenepropylene rubber (M-EPM), maleic anhydride-modified ethylene-α-olefincopolymer, ethylene-glycidyl methacrylate copolymer, maleicanhydride-modified ethylene-ethyl acrylate copolymer (modified EEA),butyl rubber (IIR), isobutylene and aromatic vinyl or diene monomercopolymer, acrylic rubber (ACM), and ionomer.

Examples of the halogen-containing rubber include halogenated butylrubber such as brominated butyl rubber (Br-IIR) and chlorinated butylrubber (Cl-IIR), a halogenated isomonoolefin-p-alkyl styrene copolymer(for example, brominated isobutylene-p-methylstyrene copolymer (BIMS)),halogenated isobutylene-isoprene copolymer rubber, chloroprene rubber(CR), hydrin rubber (CHR), chlorosulfonated polyethylene (CSM),chlorinated polyethylene (CM), and maleic acid-modified chlorinatedpolyethylene (M-CM).

Examples of the silicone rubber include methyl vinyl silicone rubber,dimethyl silicone rubber, and methylphenyl vinyl silicone rubber.Examples of the sulfur-containing rubber include polysulfide rubber.Examples of the fluororubber include vinylidene fluoride rubber,fluorine-containing vinyl ether rubber, tetrafluoroethylene-propylenerubber, fluorine-containing silicone rubber, and fluorine-containingphosphazene rubber.

Among these, a halogenated isomonoolefin-p-alkyl styrene copolymer, amaleic anhydride-modified ethylene-α-olefin copolymer, anethylene-glycidyl methacrylate copolymer, and a maleicanhydride-modified ethylene-ethyl acrylate copolymer are preferable fromthe viewpoint of air blocking property.

In the elastomer component, a blending agent generally blended in arubber composition such as another reinforcing agent (filler) such ascarbon black or silica, a softener, an antioxidant, and a processing aidmay be blended to the extent that an effect of the present invention isnot impaired.

Examples of a combination of an elastomer component with a thermoplasticresin component constituting the thermoplastic elastomer compositioninclude, but are not limited to, a combination of halogenated butylrubber with a polyamide resin, a combination of a brominatedisobutylene-p-methylstyrene copolymer rubber with a polyamide resin, acombination of butadiene rubber with a polystyrene resin, a combinationof isoprene rubber with a polystyrene resin, a combination of ahydrogenated butadiene rubber with a polystyrene resin, a combination ofan ethylene propylene rubber with a polyolefin resin, a combination ofan ethylene propylene diene rubber with a polyolefin resin, acombination of a noncrystalline butadiene rubber with a syndiotacticpoly(1,2-polybutadiene), a combination of an amorphous isoprene rubberwith trans-poly(1,4-isoprene), and a combination of a fluororubber witha fluororesin. A combination of a butyl rubber with a polyamide resin ispreferable, since it has excellent air blocking properties. Acombination of a brominated isobutylene-p-methylstyrene copolymer rubberwhich is a modified butyl rubber with nylon 6/66, nylon 6, or a blendedresin of nylon 6/66 and nylon 6 is particularly preferable in view ofcompatibility between fatigue resistance and air blocking property.

A thermoplastic elastomer composition can be produced by melt-kneading athermoplastic resin component and an elastomer component, for example,in a twin-screw kneading extruder or the like to disperse the elastomercomponent as a dispersed phase in the thermoplastic resin componentforming a matrix phase. The weight ratio of the thermoplastic resincomponent to the elastomer component is preferably, but not limited to,from 10/90 to 90/10, more preferably from 15/85 to 90/10.

The thermoplastic resin or thermoplastic elastomer composition maycomprise various additives as long as the effects of the presentinvention are not impaired.

The rubber composition constituting the layer of the rubber compositioncomprises a rubber component, a condensate of a compound represented byformula (1) and formaldehyde, a methylene donor and a vulcanizing agent.

The rubber composition comprises a rubber component, and the rubbercomponent comprises from 2.5 to 40% by weight of a halogenatedisomonoolefin-p-alkylstyrene copolymer.

The halogenated isomonoolefin-p-alkylstyrene copolymer can be producedby halogenating a copolymer of isomonoolefin and p-alkylstyrene. Themixing ratio, polymerization rate, average molecular weight,polymerization form (block copolymer, random copolymer, etc.),viscosity, halogen atom and the like of the halogenated isomonoolefinand p-alkylstyrene are not particularly limited, and may be arbitrarilyselected according to the physical properties or the like required forthe thermoplastic elastomer composition. Examples of the isomonoolefinconstituting the halogenated isomonoolefin-p-alkylstyrene copolymerinclude isobutylene, isopentene, and isohexene, and isobutylene ispreferable. Examples of the p-alkylstyrene constituting the halogenatedisomonoolefin-p-alkylstyrene copolymer include p-methylstyrene,p-ethylstyrene, p-propylstyrene and p-butylstyrene, and p-methylstyreneis preferable. Examples of the halogen constituting the halogenatedisomonoolefin-p-alkylstyrene copolymer include fluorine, chlorine,bromine and iodine, and bromine is preferable. A particularly preferablehalogenated isomonoolefin-p-alkylstyrene copolymer is a brominatedisobutylene-p-methylstyrene copolymer.

The brominated isobutylene-p-methylstyrene copolymer is a brominatedproduct of an isobutylene-p-methylstyrene copolymer having a repeatingunit represented by formula (4).

Typically, it has a repeating unit represented by formula (5).

The brominated isobutylene-p-methylstyrene copolymer is available underthe trade name EXXPRO® from ExxonMobil Chemical Company.

The rubber component comprises from 2.5 to 40% by weight of ahalogenated isomonoolefin-p-alkylstyrene copolymer based on the rubbercomponent constituting the rubber composition. The rubber componentcomprises preferably from 2.5 to 20% by weight, more preferably from 2.5to 10% by weight of a halogenated isomonoolefin-p-alkylstyrenecopolymer. When the content of the halogenatedisomonoolefin-p-alkylstyrene copolymer is too small, an effect ofimproving the adhesiveness may not be obtained. When the content of thehalogenated isomonoolefin-p-alkylstyrene copolymer is too large, areaction with a resin easily occurs during mixing or molding, and theprocessability is reduced.

The present invention has a remarkable synergistic effect that, bycombining a halogenated isomonoolefin-p-alkyl styrene copolymer with acondensate of a compound represented by formula (1) and formaldehyde anda methylene donor, the adhesive strength at the interface between thefilm of the thermoplastic resin or thermoplastic elastomer compositionand the layer of the rubber composition can be effectively improved witha relatively small amount of a halogenated isomonoolefin-p-alkyl styrenecopolymer.

Of the rubber components constituting the rubber composition, examplesof a rubber component other than a halogenated isomonoolefin-p-alkylstyrene copolymer include, but are not limited to, diene rubber and ahydrogenated product thereof, olefinic rubber, halogen-containingrubber, silicone rubber, sulfur-containing rubber, and fluoro rubber.

Examples of the diene rubber and hydrogenated product thereof includenatural rubber (NR), isoprene rubber (IR), epoxidized natural rubber,styrene butadiene rubber (SBR), butadiene rubber (BR) (high cis BR andlow cis BR), acrylonitrile butadiene rubber (NBR), hydrogenated NBR, andhydrogenated SBR.

Examples of the olefin rubber include ethylene propylene rubber (EPM),ethylene propylene diene rubber (EPDM), maleic acid-modified ethylenepropylene rubber (M-EPM), maleic anhydride modified ethylene-α-olefincopolymer, ethylene-glycidyl methacrylate copolymer, maleic anhydridemodified ethylene-ethyl acrylate copolymer (modified EEA), butyl rubber(IIR), isobutylene and aromatic vinyl or diene monomer copolymer,acrylic rubber (ACM), and ionomer.

Examples of the halogen-containing rubber include halogenated butylrubber such as brominated butyl rubber (Br-IIR) or chlorinated butylrubber (Cl-IIR), halogenated isobutylene-isoprene copolymer rubber,chloroprene rubber (CR), hydrin rubber (CHR), chlorosulfonatedpolyethylene (CSM), chlorinated polyethylene (CM), and maleic acidmodified chlorinated polyethylene (M-CM).

Examples of the silicone rubber include methyl vinyl silicone rubber,dimethyl silicone rubber, and methylphenyl vinyl silicone rubber.Examples of the sulfur-containing rubber include polysulfide rubber.

Examples of the fluororubber include vinylidene fluoride rubber,fluorine-containing vinyl ether rubber, tetrafluoroethylene-propylenerubber, fluorine-containing silicone rubber, and fluorine-containingphosphazene rubber.

Among them, from the viewpoint of co-crosslinkability with an adjacentrubber material, diene rubber, olefin rubber, and halogen-containingrubber are preferable; natural rubber, styrene butadiene rubber,butadiene rubber, isoprene rubber, butyl rubber, halogenated butylrubber, and a mixture thereof are more preferable; and a combination ofnatural rubber with styrene butadiene rubber, a combination of naturalrubber with butadiene rubber, a combination of natural rubber with butylrubber, and a combination of natural rubber with halogenated butylrubber are still more preferable.

The rubber composition comprises a condensate of a compound representedby formula (1) and formaldehyde.

In formula (1), R¹, R², R³, R⁴, and R⁵ each independently representhydrogen, a hydroxyl group, an alkyl group having 1 to 8 carbon atoms,or an alkoxy group having 1 to 8 carbon atoms.

One preferable example of the compound represented by formula (1) is onein which at least one of R¹, R², R³, R⁴, and R⁵ is an alkyl group having1 to 8 carbon atoms and the rest is hydrogen or an alkyl group having 1to 8 carbon atoms. A preferable specific example of the compoundrepresented by formula (1) is cresol.

Another preferable example of the compound represented by formula (1) isone in which at least one of R¹, R², R³, R⁴, and R⁵ is a hydroxyl groupand the rest is hydrogen or an alkyl group having 1 to 8 carbon atoms.Another preferable specific example of the compound represented byformula (1) is resorcinol (also referred to as “resorcin”).

Examples of the condensate of the compound represented by formula (1)and formaldehyde include cresol/formaldehyde condensate andresorcin/formaldehyde condensate. These condensates may be modified solong as an effect of the present invention is not impaired. For example,a modified resorcin/formaldehyde condensate which is aresorcin/formaldehyde condensate modified with an epoxy compound canalso be used in the present invention. These condensates arecommercially available and such commercially available products can beused in the present invention.

The condensate of the compound represented by formula (1) andformaldehyde is preferably a compound represented by formula (2) orformula (3).

In formula (2), n is an integer of 1 to 20, preferably an integer of 1to 10, and more preferably an integer of 1 to 5.

In formula (3), m is an integer of 1 to 20, preferably an integer of 1to 10, and more preferably an integer of 1 to 3.

The content of the condensate of the compound represented by formula (1)and formaldehyde (hereinafter sometimes simply referred to as“condensate”) is from 0.5 to 20 parts by weight, preferably from 1 to 10parts by weight based on 100 parts by weight of the rubber component.When the content of the condensate is too small, the amount of heat andtime necessary for obtaining good adhesion are increased, and therefore,the vulcanization efficiency deteriorates. When the content of thecondensate is too large, the vulcanized elongation of the obtainedrubber composition is impaired and breakage tends to occur.

The rubber composition comprises a methylene donor.

A methylene donor refers to a basic compound that generates formaldehydeby heating and the like, and examples thereof include hexamethylenetetramine, pentamethylene tetramine, hexamethylene diamine, methylolmelamine, etherified methylol melamine, modified etherified methylolmelamine, esterified methylol melamine, hexamethoxymethylol melamine,hexamethylol melamine, hexakis(ethoxymethyl)melamine, hexakis(methoxymethyl)melamine, N,N′,N″-trimethyl-N,N′,N″-trimethylolmelamine,N,N′,N″-trimethylolmelamine, N-methylolmelamine,N,N′-bis(methoxymethyl)melamine,N,N′,N″-tributyl-N,N′,N″-trimethylolmelamine, and paraformaldehyde.Among them, modified etherified methylol melamine is preferable from theviewpoint of the release temperature of formaldehyde.

The content of the methylene donor is from 0.25 to 200 parts by weight,preferably from 0.5 to 80 parts by weight, more preferably from 1 to 40parts by weight based on 100 parts by weight of the rubber component.When the content of the methylene donor is too small, the methylenedonor is consumed in the resin reaction in the rubber compositionsystem, and therefore, the reaction in the interfacial reaction does notproceed and the adhesion is deteriorated. When the content is too much,the reaction in the rubber composition system is promoted too much, orthe crosslinking reaction in the resin system to be adhered is inducedand the adhesion is deteriorated.

The ratio of the content of the methylene donor to the content of thecondensate is preferably from 0.5 to 10, more preferably from 1 to 4,and still more preferably from 1 to 3. When the ratio is too small, thedonor is consumed in the resin reaction in the rubber compositionsystem, and therefore, the reaction in the interfacial reaction does notproceed and the adhesion is deteriorated. When the ratio is too large,the reaction in the rubber composition system is promoted too much, orthe crosslinking reaction in the resin system to be adhered is induced,and the adhesion is deteriorated.

The rubber composition comprises a vulcanizing agent.

Examples of the vulcanizing agent include an inorganic vulcanizing agentand an organic vulcanizing agent. Examples of the inorganic vulcanizingagent include sulfur, sulfur monochloride, selenium, tellurium, zincoxide, magnesium oxide, and lead monoxide. Examples of the organicvulcanizing agent include a sulfur-containing organic compound, adithiocarbamate, an oxime, tetrachloro-p-benzoquinone, a dinitrosocompound, a modified phenolic resin, a polyamine, and an organicperoxide. Among them, sulfur, an organic peroxide such as1,3-bis(t-butylperoxyisopropyl)benzene, a modified phenolic resin suchas a brominated alkylphenol/formaldehyde condensate, zinc oxide, and asulfur-containing organic compound are preferable.

The content of the vulcanizing agent is preferably from 0.5 to 10 partsby weight, more preferably from 0.5 to 8 parts by weight, and still morepreferably from 0.5 to 5 parts by weight, based on 100 parts by weightof the rubber component. When the content of the vulcanizing agent istoo small, the strength of the rubber is reduced, and as a result, goodadhesiveness is not exhibited. When the content of the vulcanizing agentis too large, the adhesion reaction between the rubber and the film isinhibited.

The rubber composition may further comprise a vulcanization accelerator.

Examples of the vulcanization accelerator include analdehyde.ammonia-based, aldehyde.amine-based, thiourea-based,guanidine-based, thiazole-based, sulfenamide-based, thiuram-based,dithiocarbamate-based, and xanthogenate-based vulcanizationaccelerators. A thiazole-based, sulfenamide-based, and thiuram-basedvulcanization accelerators are preferable.

The thiazole-based vulcanization accelerator is a compound having athiazole structure, and examples thereof include di-2-benzothiazolyldisulfide, mercaptobenzothiazole, benzothiazyl disulfide, zinc salt ofmercaptobenzothiazole, (dinitrophenyl)mercaptobenzothiazole, and(N,N-diethylthiocarbamoylthio)benzothiazole. Among them,di-2-benzothiazolyl disulfide is preferable.

The sulfenamide-based vulcanization accelerator is a compound having asulfenamide structure, and examples thereof includeN-cyclohexylbenzothiazole sulfenamide, N-t-butylbenzothiazolesulfenamide, N-oxydiethylene benzothiazole sulfenamide, N,N-dicyclohexylbenzothiazole sulfenamide, and (morpholinodithio)benzothiazole. Amongthem, N-t-butyl-2-benzothiazole sulfenamide is preferable.

The thiuram-based vulcanization accelerator is a compound having athiuram structure, and example thereof includetetrakis(2-ethylhexyl)thiuram disulfide, tetramethyl thiuram disulfide,tetramethyl thiuram monosulfide, tetraethyl thiuram disulfide,tetrabutyl thiuram disulfide, and dipentamethylene thiuram hexasulfide.Among them, tetrakis (2-ethylhexyl) thiuram disulfide is preferable.

The content of the vulcanization accelerator is preferably from 0.5 to10 parts by weight, more preferably from 0.5 to 8 parts by weight, andstill more preferably from 0.5 to 5 parts by weight, based on 100 partsby weight of the rubber component. When the content of the vulcanizationaccelerator is too small, the vulcanization reaction is not completedwithin a desired vulcanization time, and therefore, the rubber strengthdecreases, and as a result, good adhesiveness is not exhibited. When thecontent of the vulcanization accelerator is too large, the adhesionreaction between the rubber and the film is inhibited.

The laminate of the present invention can be produced by laminating arubber composition on a film of a thermoplastic resin or thermoplasticelastomer composition. More specifically, although not limited, alaminate can be manufactured as follows. First, a thermoplastic resin orthermoplastic elastomer composition film is formed by molding athermoplastic resin or thermoplastic elastomer composition into a filmshape by a molding apparatus such as an inflation molding apparatus or aT die extruder. Next, the rubber composition is extruded onto the filmby a T-die extruder or the like and laminated at the same time toproduce a laminate.

The pneumatic tire of the present invention can be produced by aconventional method. For example, the laminate of the present inventionas an inner liner material is placed on the tire molding drum with theside of the film of a thermoplastic resin or thermoplastic elastomercomposition facing the tire molding drum. The members used formanufacturing ordinary tires such as a carcass layer made ofunvulcanized rubber, a belt layer, a tread layer, and the like aresequentially stuck thereon, and after molding, the drum is pulled out toobtain a green tire. Next, by heating and vulcanizing this green tireaccording to a conventional method to obtain a pneumatic tire.

EXAMPLES (1) Preparation of Rubber Composition

The following raw materials were blended at the blending ratios listedon Table 1 and Table 2 to prepare rubber compositions.

Styrene butadiene rubber: “Nipol 1502” manufactured by Zeon Corporation

Brominated isobutylene-p-methylstyrene copolymer: EXXPRO® MDX89-4manufactured by ExxonMobil Chemical Company

Natural rubber: SIR-20

Carbon black: “SEAST V” manufactured by Tokai Carbon Co., Ltd.

Stearic acid: Industrial stearic acid

Aromatic oil: “Desorex No. 3” manufactured by SHOWA SHELL SEKIYU K. K.

Zinc oxide: “Zinc Oxide No. 3” manufactured by SEIDO CHEMICAL INDUSTRYCO., LTD.

Modified resorcin/formaldehyde condensate: “Sumikanol 620” manufacturedby TAOKA CHEMICAL COMPANY, LIMITED

Methylene donor: modified etherified methylol melamine (“Sumikanol507AP” manufactured by TAOKA CHEMICAL COMPANY, LIMITED)

Sulfur: 5% oil-extended treated sulfur

Vulcanization accelerator: di-2-benzothiazolyl disulfide (“NOCCELER DM”manufactured by OUCHI SHINKO CHEMICAL INDUSTRIAL CO., LTD.)

(2) Preparation of Thermoplastic Elastomer Composition Film

One hundred (100) parts by weight of brominatedisobutylene-p-methylstyrene copolymer (EXXPRO® 3035 manufactured byExxonMobil Chemical Company), 0.5 parts by weight of zinc oxide (“ZincOxide No. 3” manufactured by SEIDO CHEMICAL INDUSTRY CO., LTD.), 0.2parts by weight of stearic acid (industrial stearic acid), 1 part byweight of zinc stearate (“Zinc stearate” manufactured by NOFCORPORATION), 100 parts by weight of nylon 6/66 (“UBE Nylon” 5033Bmanufactured by UBE INDUSTRIES, LTD.), 10 parts by weight of maleicanhydride-modified ethylene-ethyl acrylate copolymer (Rilsan® BESN 0 TLmanufactured by ARKEMA K.K.), and 20 parts by weight of plasticizer(N-butylbenzenesulfonamide “BM-4” manufactured by DAIHACHI CHEMICALINDUSTRY CO., LTD.) were mixed to prepare a thermoplastic elastomercomposition, and the thermoplastic elastomer composition was molded byan inflation molding apparatus to prepare a thermoplastic elastomercomposition film having a thickness of 0.1 mm. The preparedthermoplastic elastomer composition film is hereinafter, also referredto as “film A”.

(3) Preparation of Thermoplastic Resin Film

UBE Nylon 5033B manufactured by UBE INDUSTRIES, LTD. was molded by aninflation molding apparatus to prepare a thermoplastic resin film havinga thickness of 0.1 mm. The prepared thermoplastic resin film ishereinafter also referred to as “film B”.

(4) Preparation of Laminate

Using an extruder, the rubber composition prepared in above (1) wasextrusion-laminated on the film prepared in above (2) and (3) with athickness of 0.7 mm to prepare a laminate.

(5) Evaluation of Laminate

For the prepared laminate, the peel strength was evaluated. Theevaluation results of the laminate of the thermoplastic elastomercomposition film and the rubber composition are listed on Table 1, andthe evaluation results of the laminate of the thermoplastic resin filmand the rubber composition are listed on Table 2. The evaluation methodof peel strength is as follows.

Peel Strength

A sample of the laminate was cut to a width of 25 mm after vulcanizationand the peel strength at the interface between the film of the striptest piece and the rubber was measured in accordance with JIS-K6256. InTable 1 and Table 2, the peel strength of each example is listed as theratio to the peel strength of each comparative example (hereinafter,referred to as “peel strength index”). Incidentally, the peel strengthof Comparative Example 1 was 160 N/25 mm, and the peel strength ofComparative Example 2 was 200 N/25 mm.

TABLE 1 Comparative Example 1 Example 1 Example 2 Example 3 Example 4Example 5 Rubber Styrene butadiene rubber parts by 50 47.5 45 40 35 30composition weight Brominated isobutylene-p- parts by — 5 10 20 30 40methylstyrene copolymer weight Natural rubber parts by 50 47.5 45 40 3530 weight Carbon black parts by 60 60 60 60 60 60 weight Stearic acidparts by 1 1 1 1 1 1 weight Aromatic oil parts by 7 7 7 7 7 7 weightOxidation zinc parts by 3 3 3 3 3 3 weight Modified parts by 2 2 2 2 2 2resorcin/formaldehyde weight condensate Methylene donor parts by 4 4 4 44 4 weight Sulfur parts by 2 2 2 2 2 2 weight Vulcanization acceleratorparts by 1.5 1.5 1.5 1.5 1.5 1.5 weight Laminated film film A film Afilm A film A film A film A Peel strength index 1 1.2 1.2 1.2 1.2 1.2(The peel strength of Comparative Example 1 is set to 1)

TABLE 2 Comparative Example 2 Example 6 Example 7 Example 8 Example 9Example 10 Rubber Styrene butadiene rubber parts by 50 47.5 45 40 35 30composition weight Brominated isobutylene-p- parts by — 5 10 20 30 40methylstyrene copolymer weight Natural rubber parts by 50 47.5 45 40 3530 weight Carbon black parts by 60 60 60 60 60 60 weight Stearic acidparts by 1 1 1 1 1 1 weight Aromatic oil parts by 7 7 7 7 7 7 weightOxidation zinc parts by 3 3 3 3 3 3 weight Modified parts by 2 2 2 2 2 2resorcin/formaldehyde weight condensate Methylene donor parts by 4 4 4 44 4 weight Sulfur parts by 2 2 2 2 2 2 weight Vulcanization acceleratorparts by 1.5 1.5 1.5 1.5 1.5 1.5 weight Laminated film film B film Bfilm B film B film B film B Peel strength index 1 1.2 1.2 1.2 1.2 1.2(The peel strength of Comparative Example 2 is set to 1)

INDUSTRIAL APPLICABILITY

The laminate of the present invention can be suitably used as an innerliner material of a pneumatic tire.

1. A laminate for a pneumatic tire, comprising a film of a thermoplasticresin or a thermoplastic elastomer composition and a layer of a rubbercomposition, wherein the rubber composition comprises a rubbercomponent, a condensate of a compound represented by formula (1):

wherein R¹, R², R³, R⁴, and R⁵ are each independently hydrogen, ahydroxyl group, an alkyl group having 1 to 8 carbon atoms, or an alkoxygroup having 1 to 8 carbon atoms, and formaldehyde, a methylene donor,and a vulcanizing agent, wherein the rubber component comprises from 2.5to 40% by weight of a halogenated isomonoolefin-p-alkyl styrenecopolymer based on the rubber component, and the rubber compositioncomprises from 0.5 to 20 parts by weight of the condensate and from 0.25to 200 parts by weight of the methylene donor, based on 100 parts byweight of the rubber component.
 2. The laminate according to claim 1,wherein a ratio of a content of the methylene donor to a content of thecondensate is from 0.5 to
 10. 3. The laminate according to claim 1,wherein the thermoplastic resin is at least one selected from the groupconsisting of polyvinyl alcohol, ethylene-vinyl alcohol copolymer, nylon6, nylon 66, nylon 11, nylon 12, nylon 610, nylon 612, nylon 6/66, nylonMXD6, and nylon 6T.
 4. The laminate according to claim 1, wherein thethermoplastic elastomer composition is a composition comprising athermoplastic resin component and an elastomer component dispersed inthe thermoplastic resin component; the thermoplastic resin component isat least one selected from the group consisting of polyvinyl alcohol,ethylene-vinyl alcohol copolymer, nylon 6, nylon 66, nylon 11, nylon 12,nylon 610, nylon 612, nylon 6/66, nylon MXD6, and nylon 6T; and theelastomer component is at least one selected from the group consistingof a halogenated isomonoolefin-p-alkyl styrene copolymer, a maleicanhydride-modified ethylene-α-olefin copolymer, an ethylene-glycidylmethacrylate copolymer, and a maleic anhydride-modified ethylene-ethylacrylate copolymer.
 5. The laminate according to claim 1, wherein themethylene donor is at least one selected from the group consisting ofmodified etherified methylol melamine, paraformaldehyde,hexamethylenetetramine, pentamethylenetetramine, andhexamethoxymethylmelamine.
 6. An inner liner material for a pneumatictire, comprising the laminate according to claim
 1. 7. A pneumatic tirecomprising the laminate according to claim 1 as an inner liner material.8. The laminate according to claim 2, wherein the thermoplastic resin isat least one selected from the group consisting of polyvinyl alcohol,ethylene-vinyl alcohol copolymer, nylon 6, nylon 66, nylon 11, nylon 12,nylon 610, nylon 612, nylon 6/66, nylon MXD6, and nylon 6T.
 9. Thelaminate according to claim 2, wherein the thermoplastic elastomercomposition is a composition comprising a thermoplastic resin componentand an elastomer component dispersed in the thermoplastic resincomponent; the thermoplastic resin component is at least one selectedfrom the group consisting of polyvinyl alcohol, ethylene-vinyl alcoholcopolymer, nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, nylon 612,nylon 6/66, nylon MXD6, and nylon 6T; and the elastomer component is atleast one selected from the group consisting of a brominatedisobutylene-p-methylstyrene copolymer, a maleic anhydride-modifiedethylene-α-olefin copolymer, an ethylene-glycidyl methacrylatecopolymer, and a maleic anhydride-modified ethylene-ethyl acrylatecopolymer.
 10. The laminate according to claim 3, wherein thethermoplastic elastomer composition is a composition comprising athermoplastic resin component and an elastomer component dispersed inthe thermoplastic resin component; the thermoplastic resin component isat least one selected from the group consisting of polyvinyl alcohol,ethylene-vinyl alcohol copolymer, nylon 6, nylon 66, nylon 11, nylon 12,nylon 610, nylon 612, nylon 6/66, nylon MXD6, and nylon 6T; and theelastomer component is at least one selected from the group consistingof a brominated isobutylene-p-methylstyrene copolymer, a maleicanhydride-modified ethylene-α-olefin copolymer, an ethylene-glycidylmethacrylate copolymer, and a maleic anhydride-modified ethylene-ethylacrylate copolymer.
 11. The laminate according to claim 2, wherein themethylene donor is at least one selected from the group consisting ofmodified etherified methylol melamine, paraformaldehyde,hexamethylenetetramine, pentamethylenetetramine, andhexamethoxymethylmelamine.
 12. The laminate according to claim 3,wherein the methylene donor is at least one selected from the groupconsisting of modified etherified methylol melamine, paraformaldehyde,hexamethylenetetramine, pentamethylenetetramine, andhexamethoxymethylmelamine.
 13. The laminate according to claim 4,wherein the methylene donor is at least one selected from the groupconsisting of modified etherified methylol melamine, paraformaldehyde,hexamethylenetetramine, pentamethylenetetramine, andhexamethoxymethylmelamine.
 14. An inner liner material for a pneumatictire, comprising the laminate according to claim
 2. 15. An inner linermaterial for a pneumatic tire, comprising the laminate according toclaim
 3. 16. An inner liner material for a pneumatic tire, comprisingthe laminate according to claim
 4. 17. An inner liner material for apneumatic tire, comprising the laminate according to claim
 5. 18. Apneumatic tire comprising the laminate according to claim 2 as an innerliner material.
 19. A pneumatic tire comprising the laminate accordingto claim 3 as an inner liner material.
 20. A pneumatic tire comprisingthe laminate according to claim 4 as an inner liner material.